SLS 3D printing can create parts with a detail level comparable to injection moulding — and it does so at incredible speeds. But the technology has historically suffered from prohibitively high costs. Now, technological innovations are making it more accessible and affordable than ever.

New printers, software solutions, and other technologies bring industrial-level productivity to any business and workshop. Even small operators can now print accurate and durable parts at low price points.

SLS 3D Printing Can Be Demanding

SLS 3D printing is a powerful technology capable of making functional parts for end-use applications. It is a popular technology in many demanding industries, such as automotive, aerospace, and medical. It offers users and operators a great variety of benefits, including:

• Rapid Production: SLS is one of the faster 3D printing technologies available. The exact speed depends on the machine, but multi-laser systems can produce potentially dozens of parts in a matter of hours.

• High Productivity: SLS printers encourage you to maximise your productivity, since the more parts you build, the less waste you produce. Additionally, SLS offers one of the highest ROI rates out of any additive manufacturing method.

• Design Freedom: Unlike many other technologies, SLS parts don’t require supports. The loose powder and other parts in the print chamber support printed components, enabling you to create extremely complex geometries, like interlocking parts.

• Low Waste: It’s possible to recover and reuse up to 70% of the loose powder after a print job. Powder recycling reduces material waste and lowers material costs.

Print SLS Parts with Speed and Accuracy

But SLS technology has advanced rapidly over the past few years, with more compact and affordable machines entering the market. At the head of the pack, Formlabs Fuse 1 has changed the SLS printing landscape.

The original Fuse 1 was already fast, but the new Fuse 1+ leaves it in the dust. The upgraded printer sports a powerful 30W laser and an enhanced galvanometer for enhanced printer head movement. As a result, Fuse 1+ can achieve print speeds up to two times faster than its previous iteration.

Fuse 1+ produces parts with high durability and sharp, accurate detail, but it can now do so with more material options. Thanks to a new powder handling system and an inert nitrogen gas chamber, the Fuse 1+ can print with Nylon 11 and Nylon 12, with the latter also having glass and carbon fibre-reinforced powders available.

Harness the Latest Software Tools

SLS 3D printing relies on more than just a high-quality printer. Advanced and highly automated print preparation programmes can help businesses streamline their SLS 3D printing workflows and achieve higher levels of productivity.

One of the more popular software manufacturers in the field is Materialise with its collection of high-end 3D printing solutions. This industry-standard software has a specific Sinter Module add-on for SLS printers, which enables fast, automated print preparation processes to improve throughput and print speeds. Materialise Magics automatically handles many of the complex and time-consuming parts of SLS print preparation — such as part nesting, collision detection, and orientation optimisation.

Affordable and Efficient Post-Processing

One of the stumbling blocks of SLS 3D printing is the fact that each printed part requires post-processing. Cleaning and smoothing parts by hand is a time-consuming process. To this end, several companies have created innovative post-processing stations to get SLS parts ready for use faster and cheaper.

The AM Solutions M1 Basic is an affordable entry-level post-processing station for SLS printed parts. The machine handles powder removal and part cleaning, while also smoothing part surfaces. More demanding SLS users have found the AM Efficiency post-processing solution a welcome addition to their workflow. This 3-in-1 machine de-powders, cleans and colours, and polishes parts in a single automated process.

Enhance Your SLS 3D Printing Operation

These innovations have changed the nature of AM industry by making SLS printing faster and more accessible. What was once an exclusive technology, requiring large investments in money, time, and space, is now readily available to all 3D printing bureaus.

Modern compact and affordable SLS printers, such as Formlabs Fuse 1+, have democratised SLS printing. These machines can fit in any workshop, enabling even small businesses to open up new revenue streams. The pace of innovation has not slowed down. We don’t know what the future will bring, but it’s certainly to be excited about. Meanwhile, SLS 3D printers continue to break down barriers in the additive manufacturing industry.

Visit www.solidprint3d.co.uk